NXP TEA1832DB1253 User guide

Brand: NXP

Model: TEA1832DB1253

Type: User guide

This manual is also suitable for

UM10862

TEA1832DB1253 45 W demo board

Rev. 1.1 — 18 June 2015 User manual

Document information

Info Content

Keywords TEA1832DB1253, TEA1832TS, TEA1832LTS, notebook adapter

Abstract This user manual provides the specification, schematics and PCB layout

of the TEA1832DB1253 45 W (90 W peak) demo board. See the data

sheet and application note for more information on the TEA1832TS/LTS

IC.

User manual Rev. 1.1 — 18 June 2015 2 of 27

Contact information

For more information, please visit: http://www.nxp.com

For sales office addresses, please send an email to: [email protected]

NXP Semiconductors

UM10862

TEA1832DB1253 45 W demo board

Revision history

Rev Date Description

v.1.1 20150618 updated issue

Modifications:

• Figure 15 “TEA1832DB1253 schematic” has been updated.

v.1 20150513 first issue

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TEA1832DB1253 45 W demo board

1. Introduction

The TEA1832DB1253 demo board demonstrates the capabilities of the low-cost 6-pin

TEA1832TS/LTS Switched-Mode Power Supply (SMPS) controller. This user manual

describes the specification, the schematics, and the PCB layout of the TEA1832DB1253

45 W demo board. See the data sheet and application note for more information on the

TEA1832TS/LTS IC.

Remark: Unless otherwise specified, all values are typical values.

1.1 Features

• Low no-load power (< 55 mW at 230 V (AC), output still in regulation)

• 200 % peak power

• Universal mains supply operation

• Low ripple and noise

• Small form factor

• Low-cost design

• Efficiency DoE 2016 and COC 2014 compliant

• EMI CISPR22 compliant

• Brownin and brownout protection

• Output OverVoltage Protection (OVP)

• OverTemperature Protection (OTP)

• OverPower Protection with high/low compensation

• OverCurrent Protection (OCP)

• Output Short Circuit Protection (OSCP)

WARNING

Lethal voltage and fire ignition hazard

The non-insulated high voltages that are present when operating this product, constitute a

risk of electric shock, personal injury, death and/or ignition of fire.

This product is intended for evaluation purposes only. It shall be operated in a designated test

area by personnel qualified according to local requirements and labor laws to work with

non-insulated mains voltages and high-voltage circuits. This product shall never be operated

unattended.

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2. Safety warning

The TEA1832DB1253 demo board input is connected to the mains voltage. Avoid

touching the board while it is connected to the mains voltage and when it is in operation.

An isolated housing is obligatory when used in uncontrolled, non-laboratory environments.

Galvanic isolation from the mains phase using a fixed or variable transformer is always

recommended. Figure 1

shows the symbols on how to recognize these devices.

a. Isolated b. Not isolated

Fig 1. Isolation symbols

019aab173

019aab174

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3. Power supply specification

Table 1 lists the specification of the TEA1832DB1253 demo board.

Table 1. TEA1832DB1253 specifications

Symbol Parameter Value

input voltage 90 V to 264 V

input frequency 47 Hz to 64 Hz

input power < 55 mW; no-load

output voltage 19.5 V

o(ripple)(p-p)

ripple output voltage < 150 mV (pp); full load;

20 MHz bandwidth;

10 F capacitor at end of cable

o(nom)

nominal output power 45 W

o(peak)

peak output power > 90 W; 2 ms peak load during 50 %

continuous load; 100 V (AC); 50 Hz;

measured at end of cable

o(peak)

output voltage during peak load > 18 V; 2 ms 200 % peak load during

50 % continuous load; 100 V (AC);

50 Hz; measured at end of cable

holdup

hold-up time > 5 ms; 115 V (AC); 60 Hz; full load

startup

start-up time < 2 s; 115 V (AC); 60 Hz

<3s; 90V(AC); 60Hz

 efficiency > 89 %; average; measured at end of

cable

> 83 %; at 10 % load

> 60 %; at 0.6 % load

(= at 270 mW load)

line(reg)

line voltage regulation < 1 %; 90 V (AC) to 264 V (AC);

measured at the PCB

load(reg)

load voltage regulation < 1 %; no-load to full load (2.3 A);

measured at the PCB

EMI conducted EMI > 5 dB margin; according to CISPR22

o(opp)

OPP trigger level 50 W to 60 W; over full input voltage

range

O(ovp)

overvoltage protection output

voltage

< 24 V (DC)

brownin voltage 75 V (AC) to 85 V (AC)

brownout voltage 65 V (AC) to 75 V (AC); over full load

range

i(shorted_output)

average input power at

continuously shorted output

<1W; 264V(AC)

otp

overtemperature protection

temperature

105 C; ±5 C; diode and NTC same

temperature

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4. Board photographs

Fig 2. TEA1832DB1253 demo board photograph - Top view

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5. Performance

Performance figures are based on PCB design:

• Schematic version: v.3 (see Figure 15)

5.1 Efficiency

Efficiency measurements are taken using an automated test program containing a

temperature stability detection algorithm. The output voltage and output current are

measured using a 4-wire current sense configuration directly at the PCB connector.

Measurements are performed for:

• 115V/60Hz

• 230V/50Hz

After subtracting 0.975 % from the 4-point average efficiency result for cable losses, the

board complies with all efficiency standards listed below.

Table 2. High load efficiency

Measured directly at the PCB; see Section 5.1.1 for more information about how to calculate efficiency at end of cable.

Condition Efficiency at specified load

10 %;

4.5 W

25 %;

11.25 W

50 %;

22.5 W

75 %;

33.75 W

100 %;

45 W

4-point

average

115 V (AC)/60 Hz 88.74 % 90.24 % 90.70 % 90.01 % 89.23 % 90.05 %

230 V (AC)/50 Hz 87.52 % 88.64 % 90.33 % 90.65 % 90.46 % 90.02 %

Table 3. Low load efficiency

Measured directly at the PCB

Condition Efficiency at specified load

0.1 W;

0.22 %

0.2 W;

0.44 %

0.5 W;

1.11 %

1W;

2.22 %

2W;

4.44 %

115 V (AC)/60 Hz 69.36 % 78.35 % 85.65 % 87.77 % 88.89 %

230 V (AC)/50 Hz 56.52 % 69.12 % 80.34 % 84.02 % 86.02 %

Table 4. Efficiency standards

Standard 10 % load 4-point average

(25 %; 50 %; 75 %; 100 %)

COC 2014 78.43 % 88.43 %

COC 2016 78.85 % 88.85 %

DoE 2008 - 84.26 %

DoE 2016 - 87.73 %

Energy Star 2.0 - 86.03 %

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5.1.1 Cable loss

At full load, the cable loss reduces the efficiency by:

(1)

• The resistance of a 1.8 m 20 AWG cable is approximately 120 m which reduces the

efficiency at full load by .

• For the 4-point average, the result of the formula above must be multiplied by 0.625

so for the 4-point average the efficiency is reduced by 0.97 %.

• At a 10 % load, the influence of the cable can already be neglected.

5.1.2 Output diode

Replacing the 20 A Schottky diode (D5 in Figure 15) by a 40 A Schottky diode, for

example, the Vishay V40100C can improve the efficiency about 0.5 %.

5.2 No-load power consumption

Measurement details:

• Power meter Yokogawa WT210

• Integrated over 36 s

• AC source Agilent 6812B

• No probes or ground clips connected to board

1. At low output current, the cable losses rapidly decrease: reducing the output current by a factor 2 decreases the cable losses by a

factor 4.

Table 5. Cable loss for different types of cable

Cable thickness

(AWG)

Cable length

(m)

Resistance at 20 C

(m)

Efficiency loss

(4-point average)

(%)

16 1.2 32 0.26

1.8 47 0.39

18 1.2 50 0.41

1.8 75 0.71

20 1.2 80 0.65

1.8 120 0.97



cable

 P

nom



--------------------

100 %

nom

cable



 P

nom



--------------------------------

100 %

2.3 A

cable



0.9 45 W

----------------------------------------

100 %== =

cable

13 %=

13 % 120 m 1.56 %=

Table 6. No-load power measurements

Input condition No-load power

90 V (AC)/60 Hz 24.8 mW

115V(AC)/60Hz 27.4mW

230V(AC)/50Hz 48.8mW

264V(AC)/50Hz 58.7mW

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TEA1832DB1253 45 W demo board

5.3 Load regulation

The output voltage as a function of load current is measured directly at the PCB and at the

end of the cable at 115 V (AC)/60 Hz.

Table 7. No-load power requirements

Standard No-load power

COC 2014 150 mW

COC 2016 75 mW

DoE 2008 300 mW

DoE 2016 100 mW

Energy Star 2.0 300 mW

(1) Measured at the PCB.

(2) Measured at the end of the cable.

Fig 3. Output voltage as a function of output current

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5.4 Line regulation

The output voltage as a function of mains input voltage is measured directly at the PCB at

full load (2.3 A) and at 60 Hz.

5.5 High/low line compensation

The maximum continuous output power is measured at the PCB as function of the mains

voltage at 60 Hz.

If necessary, the OPP level can be increased by decreasing resistors R11 and R12 to

0.47  and increasing capacitor C1 to 82 F. In that case resistor R13 must be increased

to limit the output power at high input voltages. See the TEA1832 application note (Ref. 3

)

for more information about how to tune R13 and R27.

Fig 4. Output voltage as a function of mains voltage

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Fig 5. Overpower protection threshold as a function of mains voltage

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User manual Rev. 1.1 — 18 June 2015 11 of 27

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TEA1832DB1253 45 W demo board

5.6 Peak power

5.6.1 Example 1

• Load: 200 % peak (4.6 A) for 2 ms when continuously running at 50 % load (10 ms)

• Input voltage: 100 V (AC); 47 Hz

• Output voltage: remains above 18 V (18.44 V)

The output voltage was measured at end of the cable.

Green: Output voltage

Blue: Output voltage (bottom of screen is 15 V)

Fig 6. 200 % peak load for 2 ms when continuously running at 50 % load (accumulated

over 30 s)

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TEA1832DB1253 45 W demo board

5.6.2 Example 2

• Load: 200 % peak (4.6 A) for 1 ms when continuously running at 100 % load (10 ms)

• Input voltage: 90 V (AC); 47 Hz

• Output voltage: remains above 17 V (17.59 V)

The output voltage was measured at end of the cable.

For an even higher or longer peak load, decrease current sense resistor and increase bulk

capacitor (also increases the maximum continuous output power) or increase the output

capacitor.

5.7 VCC voltage

The VCC voltage is measured at different input and loading conditions. It is within a safe

margin of the UVLO level and the OVP level.

Green: Output voltage (bottom of screen is 15 V)

Fig 7. 200 % peak load for 1 ms when continuously running at 100 % load (accumulated

over 30 s)

Table 8. VCC voltage

The two voltages are the minimum and the maximum value of the VCC ripple.

Condition 90 V (AC)/60 Hz 264V(AC)/50Hz

no-load 15.55 V to 17.25 V 15.05 V to 17.40 V

90 W peak load 24.50 V to 24.95 V 24.55 V to 24.75 V

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5.8 Brownout and start-up level

Brownout and start-up level were measured at no-load and at full load in 0.5 V steps.

5.9 OverVoltage Protection (OVP)

Applying a short circuit across the LED of the photocoupler (U2) creates an output

overvoltage condition. The output voltage is measured directly at the PCB.

The OVP trigger level can be adjusted by changing resistor R27.

Table 9. Brownout and start-up level

Condition Start-up voltage Brownout voltage

no-load 83.5 V (AC) 73.5 V (AC)

full load (2.3 A) 83.5 V (AC) 75.0 V (AC)

Table 10. Maximum output voltage

Condition 115 V (AC)/60 Hz 230V(AC)/50Hz

no-load 22.75 V 22.75 V

full load (2.3 A) 22.75 V 22.75 V

(1) Orange: VCC

(2) Blue: V

Fig 8. Overvoltage protection (230 V (AC)/50 Hz; full load)

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5.10 Start-up time

The start-up time was measured without connecting any voltage probes. All capacitors

were fully discharged before starting up.

5.11 Start-up sequence

Figure 9 and Figure 10 show waveforms of some essential voltages. These waveforms

were captured during start-up at full load.

Table 11. Start-up time measured at three input voltages

Input voltage Start-up time

90 V (AC)/60 Hz 2.35 s

115V(AC)/60Hz 1.56s

230V(AC)/50Hz 0.64s

(1) Orange: VCC

(2) Magenta: CTRL

(3) Green: DRIVER

(4) Blue: V

Fig 9. Start-up waveforms at 115 V AC)/60 Hz

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TEA1832DB1253 45 W demo board

5.12 Hold-up time

The hold-up time at 115 V (AC)/50 Hz is 9.0 ms.

(1) Orange: VCC

(2) Magenta: CTRL

(3) Green: DRIVER

(4) Blue: V

Fig 10. Start-up waveforms at 230 V (AC)/50 Hz

(1) Magenta: Bulk capacitor voltage

(2) Blue: V

Fig 11. Hold-up time at 115 V (AC)/50 Hz

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TEA1832DB1253 45 W demo board

The hold-up time was measured from the last valley of the bulk capacitor ripple (worst

case moment for mains interruption) until the output voltage starts to drop (drops to below

18.5 V).

5.13 Average input power at continuously shorted output

Measurement details:

• Output was shorted at the end of the cable

• Power meter Yokogawa WT210

• Current range 5 A

• Integration time 36 s

5.14 Output ripple and noise

Measured at full load with a 10 F/50 V capacitor (United Chemi Con; KY series) at end of

the cable. The oscilloscope bandwidth was limited to 20 MHz.

Table 12. Input power at continuously shorted output

Condition Input power

90 V (AC)/60 Hz 168 mW

115V(AC)/60Hz 192mW

230V(AC)/50Hz 618mW

264V(AC)/50Hz 760mW

Table 13. Output ripple and noise

Condition V

o(ripple)(p-p)

90 V (AC) 81 mV (pp)

264 V (AC) 81 mV (pp)

Fig 12. Output voltage ripple and noise at 264 V (AC)/50 Hz

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5.15 OverTemperature Protection (OTP)

The external OTP triggers at 105 C, measured in an oven at 115 V (AC)/60 Hz at no-load

operation.

5.16 EMI performance

Conducted EMI measurement details:

• Full load (passive load 8.33  at end of cable)

• Supply voltage 115 V (AC) and 230 V (AC)

• Frequency range 150 kHz to 30 MHz

• Test receiver Rohde & Schwarz ESPI3

• Line impedance stabilization network Rohde & Schwarz ENV216

Remark: In Figure 13

and Figure 14, the blue line is the peak measurement result and the

black line is the average measurement result.

a. Line b. Neutral

Fig 13. Conducted EMI performance at 115 V (AC)/60 Hz

User manual Rev. 1.1 — 18 June 2015 18 of 27

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TEA1832DB1253 45 W demo board

a. Line b. Neutral

Fig 14. Conducted EMI performance at 230 V (AC)/50 Hz

User manual Rev. 1.1 — 18 June 2015 19 of 27

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TEA1832DB1253 45 W demo board

6. Schematic

Fig 15. TEA1832DB1253 schematic

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User manual Rev. 1.1 — 18 June 2015 20 of 27

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TEA1832DB1253 45 W demo board

7. Bill Of Materials (BOM)

Table 14. TEA1832DB1253 bill of materials

Reference Description and values Part number Manufacturer

BC1 not mounted; ferrite core; on pin CY1 74270073 Würth Elektronik

BD1 bridge diode; 2 A; 600 V KBP206G Diodes Inc.

C1 capacitor; 68 F; 400 V; 105 C 400BXW68MEFC18X20 Rubycon

C2 capacitor; 3.3 nF; 1 kV; X7R; 1206 - -

C3 capacitor; 2.2 nF; 630 V; X7R; 1206 - -

C4 capacitor; not mounted; 100 pF; 1 kV;

X7R; 1206

C7 capacitor; 100 nF; 50 V; X7R; 0603 - -

C9; C10; C15 capacitor; 1 nF; 50 V; X7R; 0603 - -

C11 capacitor; 2.2 F; 50 V; 105 C;

5mm 11 mm

50YXJ2R2MTA5X11 Rubycon

C13 capacitor; 680 F; 25 V; 105 C;

10 mm  20 mm

EKZE250ELL681MJ20S United Chemi Con

C16 capacitor; 10 nF; 50 V; X7R; 0603 - -

C18 capacitor; 220 pF; 100 V; NPO; 0805 - -

C19 capacitor; 100 nF; 50 V; X7R; 1206 - -

C20 capacitor; not mounted; 220 pF; 50 V;

X7R; 0603

CX1 capacitor; 220 nF; 275 V (AC); X2 - HJC

CY1 capacitor; 1.5 nF; 250 V (AC); Y1 DE1E3KX152MA5BA01 Murata

D1 diode; 1 kV; 2 A SA2M-E3/61T Vishay

D2 diode; 100 V; 250 mA BAS316 NXP Semiconductors

D3; D8 diode; 200 V; 200 mA BAS21H NXP Semiconductors

D5 diode; Schottky; 100 V; 2  10 A; TO220 NXPS20H100CX NXP Semiconductors

D6 diode; 85 V; 200 mA BAS416 NXP Semiconductors

D7 diode; dual; common cathode; 85 V;

100 mA

BAV70W NXP Semiconductors

D9; D10 diode; Zener; 75 V; 250 mW; SOD323F BZX84J-B75 NXP Semiconductors

F1 fuse; slow blow; 3.15 A; 250 V (AC) MST 3.15A 250V Multicomp

HS1 heat sink for Q1 - -

HS2 heat sink for D5 - -

L1 inductor; 3.3 H; 1.2 A LQM2HPN3R3MG0L Murata

LF1 choke; common mode; not mounted;

shorted by wire bridge;

diameter = 0.8 mm; pitch 5.08 mm

LF2 choke; common mode; 2  6.8 mH B82721K2122N20 EPCOS

M1; M2 screw; M3  8; for mounting Q1 and D5 - -

M3; M4 spring washer; M3;

for mounting Q1 and D5

M5; M6 nut; M3; for mounting Q1 and D5 - -

Q1 MOSFET; N-channel; 600 V; 10 A TK10A60D Toshiba

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NXP TEA1832DB1253 User guide

Brand: NXP

Model: TEA1832DB1253

Type: User guide

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NXP TEA1832DB1253 User guide

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